Electric circuit controller



United States Patent 3,327,260 ELECTRIC CIRCUIT CONTRGLLER Herman H. Murphy, 2107 W. Flower Ave., Fullerton, Calif. 92633 Filed Oct. 24, 1965, Ser. No. 504,560 6 Claims. (Cl. 335-97) This invention relates to electrical devices, and more particularly to a novel electric circuit controller for remotely controlling electrical apparatus including small electrical motors of the type used in model cars, trains, and the like.

To control miniature, electric motor-driven cars of, for example, the slot racer-type, various switching and power consuming devices have been widely used, none of which truly does a satisfactory job. The ON-OFF type of switch control, for example, is not sufliciently responsive resulting in either the power being applied too long or not long enough. The necessary sensitivity simply cannot be obtained within any economically realistic sense. The other commonly used type of controller utilizes a power consuming rheostat which, in time, as a result of heat dissipation, becomes uncomfortable for the operator and unless properly matched to the source voltage and power ratings, as well as the electrical characteristics of the particular motor driving the racer, the resulting performance of the racer is other than as desired. In brief, to achieve proper speed control when using power consuming types of controllers requires that the controller be properly matched to the source and to the load. Such conditions are not always assured, since it is common to operate the slot racer on various tracks, any or all of which may have different power supply characteristics.

These disadvantages are alleviated by the controller according to the invention. By using a vibrating-type mechanism having contact elements which may be manually positioned relative to the vibrating reed element, the operator can manually control the speed and acceleration rates of the car and, when needed or desired, can dynamically brake the miniature car. The operator is in complete control and, as a result of such control, derives more enjoyment and satisfaction than heretofore obtained.

According to the invention, there is provided an electric circuit controller for operatively controlling a small electrical motor comprising, an electrical winding having a core of ferrous material axially disposed and extending through the winding, a frame for supporting the winding and in electrical contact with one end of the Winding, a terminal block including a plurality of insulating spacers supportedly attached to the frame, a reed element mounted on the terminal block and disposed in a plane parallel to the center line of the core and at a predetermined distance therefrom, a first contact element mounted on the terminal block and spaced from the reed element a first predetermined distance, at least one of the insulating spacers being disposed between the first contact element and the reed element, lead means for providing a conductive path between the first contact element and the other end of the winding, a second contact element mounted on the terminal block and spaced from the reed element a second predetermined distance, at least one of the insulating spacers being disposed between'the second contact element and the reed element, the reed element being positioned intermediate the first and second contact elements, a source of electrical power connected across the reed element and the frame, means for connecting the small electrical motor across the second con- 'tact element and the frame, and actuating means including a rod intercoupling the second contact element and "ice the reed element in a predetermined sequence with the first contact element and a lever pivotally mounted to the frame and in contact relationship with the rod, the rod including two spaced apart sleeves of non-conductive material, each of the sleeves being disposed in force transmitting relationship with the second contact element and with the reed element at the corresponding outer surfaces thereof to permit the reed element to engage the first contact element as the rod is displaced upon movement of the lever before the second contact element engages the reed element when the rod is fully displaced.

It is therefore the primary objective and purpose of this invention to provide an improved electric circuit controller for small motors and the like.

Another object of the invention is to provide an electric circuit controller that consumes a minimum of power available for driving a small motor of the type used in miniature cars.

Another object of the invention is to provide an electric circuit controller of the type described for controlling the speed of small motors of the type used in model racing cars and the like.

Still another object of the invention is to provide an electric circuit controller of the type described wherein the operator of a model racing car and similar device driven by a small motor is able to dynamically brake the controlled device as well as regulate the speed of such a device over a wide range of voltage levels including the maximum voltage available.

Yet another object of the invention is to provide an electric circuit controller of the type described for controlling the voltage waveform to a utilization device, which controller utilizes a winding and vibrating reed, the frequency and displacement of which are uniquely controlled manually.

It is another object of the invention to provide an electric circuit controller which utilizes a vibrating mechanism, the sound and vibration of which serve as addition inputs from which the operator can realistically judge the performance of the device being remotely controlled.

Other objects and advantages of the invention will appear and be brought out more fully in the following specification, reference being had to the accompanying drawing, wherein:

FIGURE 1 is a perspective view of an electric circuit controller constructed in accordance with the invention;

FIGURE 2 is a partial cross sectional view of a controller of FIGURE 1, showing the operative elements with the actuating mechanism in a normally ofl? position;

FIGURE 3 is a partial cross sectional view of a controller of FIGURES 1 and 2, showing a portion of the actuating mechanism initially displaced a small amount for descriptive purposes;

FIGURE 4 is a partial cross sectional view of a controller of FIGURES 1 and 2, with the actuating mechanism shown in FIGURE 3 further displaced to energize the coil winding;

FIGURE 5 is a partial cross sectional view of a controller of FIGURES 1 and 2, with the actuating mechatroller is pivotally mounted on the outside of the housing 13 by a pivot pin 15. A cable 16, extending from the lower end of the controller 10, includes a power-in clip lead 18, a ground clip lead 19 which may be the stranded shield of the cable 16, and a power-out construction clip lead 20.

As best seen in FIGURES 2 thru 5, inclusive, leads 18, 19, and 20 are terminated inside the housing 13 at a terminal block 22. Insulating spacers 23 are provided on the terminal block 22 to prevent an electrical short circuit. The block 22 also includes a resilient contact element 24, an armature or vibrating reed element 25, and another resilient contact element 26, each of the elements 24, 2'5, and 26 being suitably separated by the other by one or more spacers 23.

The contact elements 24 and 26 each includes contact points 24a and 2611 respectively on that side which faces the reed element 25. In turn, the reed element 25 includes contact points 25a and 25b for engaging the contact points 24a and 26a respectively.

A threaded fastener 27 is provided to mount the terminal block 22 together with the elements 24, 25, and 26 and the spacers 23 to a frame 28. Conventional cap screws 29 and 30 may be provided to attach the frame 28 to the housing 13. If desired, bushings 31 may be used to centrally position the frame 28 and the terminal block 22 in the housing 13.

The upper end of the frame 28, which may have an inverted L shaped configuration, serves as a support for a winding 34 having a core, not shown. One end of the winding 34 is connected to the contact element 26 by a conductor 35 and the other end, not shown, of the winding 34 is connected internally to the frame 28.

The reed element 25 extends upwardly from the terminal block 22, as shown in FIGURE 2, towards the winding 34 and is suitably positioned by the insulating spacers 23 so that the center line of the winding 34, hence the core, not shown, parallels the plane defined by the reed element 25. Stated differently, the center line of the winding 34, when extended, does not pass through the reed element 25 but instead parallels the reed element 25 at a slight distance therefrom. In the embodiment shown in FIGURE 2, for reasons to be described, the reed element 25 is positioned slightly to the right of the center line of the winding 34.

An opening 42 in the frame 28, reference FIGURES 3 and 4, is provided to receive a threaded stud '43 having a bore 44. A conventional nut may be used to secure the stud 43 in place.

A pin 36 is carried in the bore 44 and engages a rod 38 having an inner insulating sleeve 37 and an outer insulating sleeve 39. The outer ends of the sleeves 37 and 39 are attached to the rod 38, which is longer by a predetermined amount than the combined length of both sleeves 37 and 39.

Extending through the elements 24, 25, and 26, and in alignment with the bore 44 are openings, not shown, the latter being of a diameter greater than the sleeve 39 with the other two having a diameter greater than the rod 38 but less than the outside diameter of the sleeves 37 and 39. Thus, as seen in FIGURE 2, the sleeves 39 may be moved to the right or left accordingly as the pin 36 is moved without imposing a force of any kind on the contact element 26. However, as seen in FIGURES 2, 3, and 4, as the pin 36 is moved progressively more to the right as depicted by the arrows and 51 respectively, both the contact element 24 and the reed element 25 are moved to the right with the spacing therebetween remaining constant and equal to the predetermined distance between the sleeves 37 and 39.

It will be recalled that the rod 38 passes through the opening, not shown, in the contact element 24 and the reed element 25 but the sleeves 37 and 39, which are atinstead engage, respectively, with the contact element 24 and the reed element 25. Thus, by either bending theelements 24 and 25 in an appropriate manner or by suitably spacing the elements 24 and 25 apart with the insulating spacers 23 when assembling the terminal block 22, the proper spring bias can be established which will cause the reed element 25 to follow the sleeve 39 as the rod 38 is displaced by a force applied through the lever 14 to the pin 36. Thus, when a force is applied to the pin 36 to displace the rod 38 the desired maximum amount of travel, as depicted by the arrow 52 in FIGURE 5, the reed element 25 has already engaged the contact element 26 as shown in FIGURE 5 by the space between the reed element 25 and the sleeve 39. It is to be noted that the sleeve 37 is always in contact with the contact element 24.

When all forces are removed from the .pin 36, the energy stored in the contact element 24 is converted to urge the sleeve 37, and hence the rod 38, to the left; eventually, as the sleeve 39 engages the reed element '25, the reed element 25 is likewise displaced to the left of its normal free standing position along with the contact element 24 until the contact element 24 reaches its limit of travel to the left. In this left-most position, the contact element 24 makes contact with a stationary contact 40, as shown in FIGURE 2, to establish a low resistance path between the power-out clip lead 20 and the ground clip lead 19 through the frame 28 to which the stationary contact 40 is attached by means of the threaded stud 43 and the nut 45.

An opening 48 in axial alignment with the bore 44 is provided in the housing 13, reference FIGURES 2 and 4. A pivot pin support bracket 42, which is attached to the housing 13 and to the frame 28 by the cap screw 30, may extend through the opening 48 to receive the pivot pin 15 for operatively mounting the lever 14 to the con-' troller 10. The pin 36, disposed in the bore 44, has a length sufiicient to engage the lever 14 and the rod 38 at the outer end of the sleeve 37 when the lever 14 is positioned in the manner shown in FIGURE 2, i.e., the off or inoperative position. Thus, by applying a force to the lever 14 to cause clock-wise rotation about the pivot point 15, the pin 36, and hence the rod 38 and the sleeves 37 and 39, is displaced to the right in FIGURES 2 through 5, inclusive.

The geometry of the lever 14 and the positioning of the bracket 42 may be utilized to limit the travel of the pin 36 to that necessary to cause the contact element 24 to engage the reed element 25 after the contact element 26 has been engaged by the reed element 25, as shown in FIGURE 5 and depicted by the arrow 52. Under such circumstances, the reed element 25 is restrained from vibrating and the power supplied to the power-in clip lead 18 is applied to the power-out clip lead 20 by way of the reed element 25 and the contact element 24.

In FIGURE 6, a waveform 55 graphically describes the periodic voltage available across the frame 28 and the contact element 24 meaning the voltage supplied to the power-out clip lead 28 relative to the ground clip lead 19. The waveform 55 is obtained by rotating the lever 14 clock-wise from the position shown in FIGURE 2 enough to break contact between the stationary contact 40 and the contact element 24 as shown in FIGURE 3, and yet just enough to make contact with the reed element 25 and the contact element 26 as shown in FIG- URE 4. With the elements 24, 25, and 26 initially disposed in this manner, the winding 34 is energized, power flowing from the source, not shown, through the power-in clip lead, tothe reed element 25 hence to the contact element 26 via contact points 25b and 26a, through the conductor 25 to the Winding 34, and returning to the ground clip lead 19 through the frame 28 to the original source. Once energized, the reed element 25 responds to the magnetic field developed by the winding 34 causing the contact points 25b and 26a to separate and the contact points 25a and 24a to engage and provide a low resistance path for power to flow from the power-in clip lead 18 to the power-out clip lead 20 through the reed element 25 and the contact element 24. The separation of the contact points 25b and 26a interrupts the power flow to the Winding 34 which is thereby dc-energized and the magnetic field previously established destroyed.

As the reed element 25 was pulled toward the contact element 24 due to the magnetic field, mechanical energy was stored in the resilient reed element 25, which, as stated above, also has been spring biased in the opposite direction, i.e. towards the contact element 26. With the break-down of the magnetic field, the reed element 25 is returned to again engage the contact element 26 via the contact points 25b and 26a to energize the winding 34 and repeat the cycle described.

The period to complete one cycle is shown graphically in FIGURE 6 as 1 The shaded area of the waveform 55 represents that amount of time during which the reed element 25 makes contact with the contact element 24 which means, the length of time during which the full voltage of the power source, not shown, is applied to the utilization device via the power-out clip lead 20 and the ground clip lead 19.

By rotating the lever 14 still further in a clockwise direction, the contact element 24 is moved by the rod 38 and the sleeve 37 still further towards the reed element 25 and the contact element 26. This results in a shorter distance over which the reed element 25 can periodically travel. This in turn decreases the period slightly from t to 1 as shown by a waveform 56 in FIGURE 6 and results in a slightly longer on or dwell time during which power is applied to the utilization device. A waveform 57 in FIGURE 6 illustrates the output characteristics of the controller when the lever 14 is rotated even further in the clockwise direction. Here again, the frequency has increased slightly as shown by a still shorter time period t and a corresponding increase in dwell time represented by the shaded areas under the waveform 57.

A curve 60 representing the electrical output of the controller 10, which may be represented in voltage units, is shown in FIGURE 7 as a function of position of the lever 14 and hence the rod 38 and the relative position of the elements 24, 25, and 26. Assuming that the contact element 24 immediately breaks from the stationary contact 40 as the lever 14 is actuated, the voltage out increases substantially linearly with displacement of the lever 14 over a range 58 until that point at which the contact element 24 engages the reed element 25. At this .point, the output voltage is discontinuous, as depicted by a dashed portion 61, and equal to the voltage level of the source as shown by a flat portion 59 of the curve 60. In other words, over a substantially large range of allowable travel of the lever 14, the electrical output of the controller 10 is substantially linear until at some point, the vibratory action ceases and the controller 10 henceforth responds as a switch which is closed providing circuit continuity between the source of power and the utilization device.

The controller 10 of the invention is particularly suitable for controlling miniature cars of the slot racer type because the full voltage available may be applied for rapid starting, if desired, or the voltage may be varied to maintain a desired speed. In addition, by releasing the lever 14 so that the contact element 24 engages the stationary contact 40, a short circuit can be established across the rminiature car to brake speed as desired. Since the reed element 25 and the contact element 26 are not engaged in contact relationship when the contact element 24 engages the stationary contact 44), such a short circuit is totally isolated from the power supply circuit.

Thus there has been described a novel electric circuit controller which aifords realistic control of miniature cars, trains, and the like. With such a controller, the operator is in complete command, being able to control not only the speed and acceleration, but also braking action. A minimal amount of power available is consumed by the controller thereby making available to the object controlled a larger amount of power than heretofore. The electrical characteristics also remain substantially unchanged, unlike the power rheostat type of controller the resistance of which may change significantly during prolonged operation. In addition, the vibratory motion and the sound attendant therewith constitute additional inputs to the operator from which to constantly judge the operation and performance of the object controlled.

While I have herein shown and described my invention in what I have conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom within the scope of my invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent devices and methods.

I claim:

1. An electric circuit controller for operatively controlling a small electrical motor comprising,

an electrical winding having a core of ferrous material axially disposed and extending through said winding;

a frame for supporting said winding and in electrical contact with one end of said winding;

a terminal block including a plurality of insulating spacers supportedly attached to said frame;

a reed element mounted on said terminal block and disposed in a plane parallel to the centerline of said core and at a predetermined distance therefrom;

a first contact element mounted on said terminal block and spaced from said reed element a first predetermined distance, at least one of said insulating spacers being disposed between said first contact element and said reed element;

lead means for providing a conductive path between said first contact element and the other end of said winding;

a second contact element mounted on said terminal block and spaced from said reed element a second predetermined distance, at least one of said insulating spacers being disposed between said second contact element and said reed element, said reed element being positioned intermediate said first and second contact elements;

a source of electrical power connected across said reed element and said frame;

means for connecting said small electrical motor across said second contact element and said frame; and

actuating means including a rod intercoupling said second contact element and said reed element in a predetermined sequence with said first contact element and a lever pivotally mounted to said frame and in contact relationship with said rod, said rod including two spaced apart sleeves of non-conductive material, each of said sleeves being disposed in force transmitting relationship with said second contact element and with said reed element at the corresponding outer surfaces thereof to permit said reed element to engage said first contact element as said rod is displaced upon movement of said lever before said second contact element engages said reed element when said rod is fully displaced.

2. The electric circuit controller in accordance with claim 1 further characterized in that there is included a stationary contact supportedly mounted to said frame and in contact relationship with said second contact element when said rod is disposed in its normally off position to provide a conductive path between said second contact element and said frame, said conductive path being interrupted as said rod is initially displaced before said reed element engages said first contact element to establish circuit continuity between said reed element and said winding by way of said first contact element and said lead means.

3. The electric circuit controller in accordance with claim 2 wherein said second contact element is spring biased to urge said second contact element outwardly away from said reed element and said first contact element towards said stationary contact, and wherein said reed element is spring biased to urge said reed element towards said first contact element.

4. The electric circuit controller in accordance with claim 3 wherein each of said elements include contact points in substantially linear alignment relative to each other, the contact points associated with said first and second contact elements being disposed on that side thereof facing the contact points disposed on each side of said reed element, and wherein said second contact element includes contact points disposed to engage said stationary contact when zero force is exerted on said lever.

5. The electric circuit controller in accordance with claim 4 further characterized in that there is provided a housing adapted to receive threaded fasteners for mounting said frame to said housing, said housing further including an opening for receiving said rod and for receiving a bracket mounted on said frame, said rod having a predetermined length to be engaged by said lever and said bracket including a pivot mounting for receiving a pin associated with said lever to mount said lever in operative disposition therewith to manually control said small electric motor.

6. The electric circuit controller in accordance with claim 4 wherein said reed element includes a coextending resilient member having a predetermined Weight disposed at the outer end thereof near said coil and off-center from said core to regulate the frequency at which said reed element vibrates as said rod is displaced by said lever.

References Cited UNITED STATES PATENTS 2,443,019 6/1948 Aust et al. 33588 2 2,675,440 4/1954 Reifel 200l66 2,691,707 10/1954 Lovejoy 200166 BERNARD A. GILHEANY, Primary Examiner.

H. BROOME, Assistant Examiner. 

1. AN ELECTRIC CIRCUIT CONTROLLER FOR OPERATIVELY CONTROLLING A SMALL ELECTRICAL MOTOR COMPRISING, AN ELECTRICAL WINDING HAVING A CORE OF FERROUS MATERIAL AXIALLY DISPOSED AND EXTENDING THROUGH SAID WINDING; A FRAME FOR SUPPORTING SAID WINDING AND IN ELECTRICAL CONTACT WITH ONE END OF SAID WINDING; A TERMINAL BLOCK INCLUDING A PLURALITY OF INSULATING SPACERS SUPPORTEDLY ATTACHED TO SAID FRAME; A REED ELEMENT MOUNTED ON SAID TERMINAL BLOCK AND DISPOSED IN A PLANE PARALLEL TO THE CENTERLINE OF SAID CORE AND AT A PREDETERMINED DISTANCE THEREFROM; A FIRST CONTACT ELEMENT MOUNTED ON SAID TERMINAL BLOCK AND SPACED FROM SAID REED ELEMENT A FIRST PREDETERMINED DISTANCE, AT LEAST ONE OF SAID INSULATING SPACERS BEING DISPOSED BETWEEN SAID FIRST CONTACT ELEMENT AND SAID REED ELEMENT; LEAD MEANS FOR PROVIDING A CONDUCTIVE PATH BETWEEN SAID FIRST CONTACT ELEMENT AND THE OTHER END OF SAID WINDING; A SECOND CONTACT ELEMENT MOUNTED ON SAID TERMINAL BLOCK AND SPACED FROM SAID REED ELEMENT A SECOND PREDETERMINED DISTANCE, AT LEAST ONE OF SAID INSULATING SPACERS BEING DISPOSED BETWEEN SAID SECOND CONTACT ELEMENT AND SAID REED ELEMENT, SAID REED ELEMENT BEING POSITIONED INTERMEDIATE SAID FIRST AND SECOND CONTACT ELEMENTS; A SOURCE OF ELECTRICAL POWER CONNECTED ACROSS SAID REED ELEMENT AND SAID FRAME; 